Chapter 1 Routine maintenance and servicing

Suspension and steering 10•99.6 Prise the grease retainer from the hubbore9.7 Removing a bearing cone from the hubbore9.8 Removing bearing cups6 Use a screwdriver or suitable lever to prisefree the grease retainer (seal) from the hubbore, but take care not to damage the boresurface (see illustration).7 Remove the inner and outer bearing conesfrom the bore of the hub (see illustration).8 To remove the bearing cups from the hub,drive them out using a suitable punch. Driveeach cup from its respective end by tapping italternately at diametrically-opposed points(see illustration). Do not allow the cups to tiltin the bore, or the surfaces may becomeburred and prevent the new bearings fromseating correctly as they are fitted.9 Clean the bore and spindle thoroughlybefore reassembly.10 To reassemble, tap the new bearing cupsinto position in the hub, using a piece oftubing slightly smaller in its outside diameterthan that of the bearing cup. Ensure that thecups are squarely inserted and abut theirrespective shoulders in the hub.11 Pack the inner bearing cone with thespecified grease, and insert it into its cup inthe hub.12 To fit the grease retainer (seal), firstlubricate its inner lip to ease installation, thenlightly tap the seal into position using a blockof wood. Ensure that the seal is correctlyorientated.13 Pack the outer bearing cone with thespecified grease, and fit it into position in itscup.14 The brake drum/hub can now be refittedto the axle spindle. Before fitting into position,first check that the brake surface area inthe drum is free of grease and oil. Locate thedrum/hub into position, then fit the retainingnut. Tighten it to the specified torque settingwhilst simultaneously rotating the assembly toensure that the bearings are correctly seated.15 Carefully tap the new hub grease cap intoposition in a progressive manner around itsouter edge until it is fully fitted.16 Refit the rubber blanking plug to the brakebackplate, and firmly apply the footbrake afew times to take up the brake adjustment.Check that the rear brakes do not bind whenthe brakes are released. Refit the roadwheel,lower the vehicle and then tighten theretaining nuts to the specified torque setting.10 Rear strut (all models exceptCourier) - removal andrefitting3Removal1 Chock the front wheels then jack up therear of the car and support it on axle stands(see “Jacking and Vehicle Support”).2 On ABS-equipped models, unscrew theretaining nuts and detach the loadapportioningvalve connecting links from theaxle beam.3 Support the relevant trailing arm of the axleassembly and unscrew and remove thesecuring bolt from the strut-to-axle mounting(see illustration).4 Prise free the protective cap from the top ofthe strut mounting, located in the luggagecompartment (see illustration).5 Unscrew and remove the two retaining nutsto detach the strut from its upper mounting.Do not unscrew the central upper mountingbolt.6 Lower the trailing arm slightly to allow thelower suspension strut mounting to clear itsaxle location, and withdraw the suspensionstrut from the vehicle.Refitting7 Refitting is a reversal of the removalprocedure, but note the following specialpoints:10.3 Lower suspension strut-to-axlemounting bolta) With the suspension strut located to itsupper mounting, tighten the retaining nutsto the specified torque.b) When reconnecting the suspension strutto the lower mounting, hand-tighten theretaining bolt, then lower the vehicle sothat it is standing on its wheels beforefully tightening the bolt to its specifiedtorque.11 Rear strut (all models exceptCourier) - dismantling, 4examination and reassemblyWarning: Before attempting todismantle the suspension strut,a suitable tool to hold the coilspring in compression must beobtained. Adjustable coil springcompressors which can be positivelysecured to the spring coils are readilyavailable, and are recommended for thisoperation. Any attempt to dismantle thestrut without such a tool is likely to resultin damage or personal injury.Dismantling1 With the strut removed from the vehicle,clean away all external dirt, then secure it in avice.2 Fit the spring compressor tool (ensuringthat it is fully engaged) and compress the coilspring until all tension is relieved from theupper mounting.10.4 Suspension strut top-mount nuts (A),and spring retaining through-bolt fixing (B)101595Ford Fiesta Remake